Color filter substrate and display apparatus using the same

ABSTRACT

A color filter substrate includes: an insulating transparent substrate; a color filter layer provided on the insulating transparent substrate, including a plurality of colored layers and constituting an in-screen display region; and an in-screen frame region defined around the in-screen display region. A light-blocking layer is provided in the in-screen frame region to cover the insulating transparent substrate. A first spacer part and a second spacer part are formed in the in-screen frame region and the in-screen display region, respectively, and are oriented substantially perpendicularly to the insulating transparent substrate. The sum of the height of the first spacer part and the thickness of the light-blocking layer is substantially equal to the sum of the height of the second spacer part and the thickness of the color filter layer.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Divisional of co-pending U.S. patent applicationSer. No. 11/073,693 which claims priority of Japanese Patent ApplicationNo. 2004-75193 filed on Mar. 16, 2004, including specification, drawingsand claims is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a color filter substrate for use in acolor liquid crystal display apparatus and a display apparatus using thecolor filter substrate.

2. Description of the Prior Art

Liquid crystal display apparatuses have features such as small size,small thickness, low power-consumption and light weight, and thereforeare widely used in various electronic equipment. In particular, activematrix liquid crystal display apparatuses including switching elementsare widely adopted in office automation equipment such as personalcomputers, AV equipment such as television sets and portable informationequipment such as cellular phones. In addition, in recent years, thesize of liquid crystal display apparatus has rapidly increased anddisplay quality of the apparatus such as definition, pixel effectivearea ratio (i.e., aperture ratio), viewing angle and color purity hasbeen rapidly improved.

The liquid crystal display apparatus includes an active matrix substrateand a color filter substrate opposing to each other and also includes aliquid crystal layer sandwiched and held between these substrates.

The thickness of this liquid crystal layer is called a cell gap or acell thickness and is defined in such a manner that plastic beads with agiven size are sprayed onto the active matrix substrate or the colorfilter substrate and the plastic beads are sandwiched and held asspacers between the substrates.

In this method of spraying spacers, plastic beads are generally sprayedby airflow, so that the locations of the plastic beads cannot beidentified. Accordingly, beads spacers distributed at random locationsin a pixel cause scattering or transmission of light, so that theproblem of degradation of display quality arises in the liquid crystaldisplay apparatus.

In each of the active matrix substrate and the color filter substrateconstituting the liquid crystal display apparatus, an in-screen displayregion in which a large number of pixels as minimum units of an imageand an in-screen frame region located around the periphery of thein-screen display region are defined.

The liquid crystal display apparatus is mounted on a casing or a framehaving an opening. The in-screen display region and the in-screen frameregion are located in the opening and a portion surrounding the opening,respectively.

In the in-screen display region of the active matrix substrate, aplurality of gate lines and a plurality of source lines are arranged tobe orthogonal to each other and a switching element is provided at eachintersection between the gate lines and the source lines. A pixelelectrode constituting a pixel is provided in each region surroundedwith a pair of gate lines and a pair of source lines.

In the in-screen frame region of the active matrix substrate, extendedlines of the gate lines and the source lines in the in-screen displayregion and auxiliary lines for defect correction or inspection arearranged. A light-blocking layer is provided on the entire in-screenframe region.

The in-screen frame region is not directly related to image display andincludes a light-blocking layer for blocking light from a backlight orthe like that is necessary for image display in the in-screen displayregion. If the light-blocking layer is made of a photosensitive resin,this layer needs to be thick in order to enhance the light-blockingproperty. In addition, in the case of mounting the liquid crystaldisplay apparatus on a casing or a frame, the light-blocking layer inthe in-screen frame region coincides with the portion surrounding theopening thereof, so that the light-blocking layer needs to be wide inconsideration of a mounting margin.

Accordingly, if this light-blocking layer is provided in the in-screenframe region, a level difference occurs between the in-screen displayregion and the in-screen frame region, so that the cell thicknessdiffers between these regions. This difference in the cell thicknesscauses a phase difference (retardation) in display light near theboundary between the in-screen display region and the in-screen frameregion, so that color irregularities due to variation of a color tonemight be perceived.

In view of this, to identify the locations of spacers and to suppresscolor irregularities occurring near the boundary between the in-screendisplay region and the in-screen frame region, a method of providingcolumnar spacers made of, for example, a resin on a color filtersubstrate was proposed.

In Japanese Patent Publication No. 8-114809, a technique of providingdummy spacers in the outside of an effective screen is disclosed.However, no preferable configuration and locations of the dummy spacersare specifically described.

In Japanese Patent Publication No. 10-82909, columns are formed on aperipheral portion of a substrate coated with a seal member so as toobtain the function of controlling a gap between the substrate and anopposed substrate (a color filter substrate.) However, no specificconfiguration of the columns is described.

In Japanese Patent Publication No. 2001-100221, a technique of formingspacers with a uniform thickness by utilizing a dry-film laminatingprocess during formation of a color filter is disclosed.

In Japanese Patent Publication No. 2001-51266, a technique of providingspacers in an in-screen display region, an in-screen frame region and anon-display region at the outer periphery of the in-screen frame regionis disclosed. However, no thickness relationship among the spacers isspecifically described.

SUMMARY OF THE INVENTION

However, in these conventional methods for forming spacers, spacers areonly formed in specific locations on a color filter substrate, andoccurrence of color irregularities near the boundary between thein-screen display region and the in-screen frame region is notsuppressed.

It is therefore an object of the present invention to provide a colorfilter substrate for suppressing occurrence of color irregularities nearthe boundary between the in-screen display region and the in-screenframe region and a display apparatus using the color filter substrate.

To achieve the object, according to the present invention, spacers areprovided on a color filter substrate or a color filter substrateconstituting a display apparatus so as to adjust the cell thickness.

Specifically, a color filter substrate according to the presentinvention includes: a transparent substrate; a color filter layerprovided on the transparent substrate, including a plurality of coloredlayers and constituting an in-screen display region; and an in-screenframe region defined around the in-screen display region, wherein alight-blocking layer is provided in the in-screen frame region to coverthe transparent substrate, a first spacer part and a second spacer partare formed in the in-screen frame region and the in-screen displayregion, respectively, and are oriented substantially perpendicularly tothe transparent substrate, and the sum of the height of the first spacerpart and the thickness of the light-blocking layer is substantiallyequal to the sum of the height of the second spacer part and thethickness of the color filter layer.

In this structure, the first and second spacer parts are formed in thein-screen frame region and the in-screen display region, respectively,of the color filter substrate to be oriented substantiallyperpendicularly to the transparent substrate provided at the base of thesubstrate. In addition, the sum of the height of the first spacer partand the thickness of the light-blocking layer is substantially equal tothe sum of the height of the second spacer part and the thickness of thecolor filter layer. Accordingly, the upper edge of the first spacer partin the in-screen frame region and the upper edge of the second spacerpart in the in-screen display region are substantially at the samelevel. This eliminates the level difference between the in-screen frameregion and the in-screen display region due to the presence of thelight-blocking layer provided in the in-screen frame region. As aresult, occurrence of color irregularities near the boundary between thein-screen display region and the in-screen frame region is suppressed.

In the color filter substrate according to the present invention, thelight-blocking layer may be thicker than the color filter layer, and theheight of the first spacer part may be smaller than that of the secondspacer part.

With this structure, if the light-blocking layer in the in-screen frameregion is thicker than the color filter layer in the in-screen displayregion, the height of the first spacer part in the in-screen frameregion is smaller than that of the second spacer part in the in-screendisplay region, so that the sum of the height of the first spacer partand the thickness of the light-blocking layer is substantially equal tothe sum of the height of the second spacer part and the thickness of thecolor filter layer. Accordingly, the upper edge of the first spacer partin the in-screen frame region and the upper edge of the second spacerpart in the in-screen display region are substantially at the samelevel.

In the color filter substrate according to the present invention, ablack matrix for preventing light from reaching portions between thecolored layers may be provided between the colored layers in the colorfilter layer.

In the color filter substrate according to the present invention, thesecond spacer part may be located in such a manner that the black matrixoverlays the second spacer, and the sum of the height of the firstspacer part and the thickness of the light-blocking layer may besubstantially equal to the sum of the height of the second spacer partand the thickness of the black matrix.

In this structure, the black matrix formed between the plurality ofcolored layers in the color filter layer overlays the second spacer partin the in-screen display region. Accordingly, even if scattering ortransmission of light is caused by the second spacer part displayquality in the screen is not degraded. In addition, the sum of theheight of the first spacer part and the thickness of the light-blockinglayer is substantially equal to the sum of the height of the secondspacer part and the thickness of the black matrix, so that the upperedge of the first spacer part in the in-screen frame region and theupper edge of the second spacer part in the in-screen display region aresubstantially at the same level. This eliminates the level differencebetween the in-screen frame region and the in-screen display region dueto the presence of the light-blocking layer provided in the in-screenframe region. As a result, occurrence of color irregularities near theboundary between the in-screen display region and the in-screen frameregion is suppressed.

In the color filter substrate according to the present invention, thelight-blocking layer may be thicker than the black matrix, and theheight of the first spacer part may be smaller than that of the secondspacer part.

In this structure, if the light-blocking layer in the in-screen frameregion is thicker than the black matrix in the in-screen display region,the height of the first spacer part in the in-screen frame region issmaller than that of the second spacer part in the in-screen displayregion, so that the sum of the height of the first spacer part and thethickness of the light-blocking layer is substantially equal to the sumof the height of the second spacer part and the thickness of the blackmatrix. Accordingly, the upper edge of the first spacer part in thein-screen frame region and the upper edge of the second spacer part inthe in-screen display region are substantially at the same level.

In the color filter substrate according to the present invention,colored layers associated with red, green and blue, respectively, may bearranged in the color filter layer, and the light-blocking layer may beformed by stacking materials constituting the colored layers associatedwith red and blue, respectively, in the color filter layer.

In this structure, the light-blocking layer in the in-screen frameregion is formed by stacking materials constituting the red and bluecolored layers in the color filter layer. That is, the light-blockinglayer is formed by the same process as that for the red and blue coloredlayers in the color filter layer, so that the process of fabricating thecolor filter substrate is simplified. In addition, out of red, green andblue colored layers, the combination of the red and blue colored layersexhibits the lowest light transmittance, so that the light-blockinglayer having a sufficient light-blocking property is formed by utilizingformation of the colored filter layer.

In the color filter substrate according to the present invention, thesecond spacer part may be formed by stacking a material constituting thefirst spacer part and a material constituting at least one of thecolored layers in the color filter layer.

In this structure, the second spacer part in the in-screen displayregion is formed by stacking the material constituting the first spacerpart in the in-screen frame region and the material constituting atleast one of the colored layers in the in-screen display region.Accordingly, the height of the second spacer part is larger than that ofthe first spacer part by the thickness of the colored layer, so that theupper edge of the first spacer part in the in-screen frame region andthe upper edge of the second spacer part in the in-screen display regionare at the same level.

In the color filter substrate according to the present invention, liquidcrystal molecules may be oriented with respect to a side of thetransparent substrate toward the color filter layer, and the in-screendisplay region may include a projection made of a material constitutingthe first and second spacer parts and used for controlling orientationof the liquid crystal molecules.

In this structure, a projection made of the material constituting thefirst and second spacer part is provided in the in-screen displayregion, so that orientation of liquid crystal molecules is controlled byutilizing this projection.

In the color filter substrate according to the present invention, thecolor filter layer, the light-blocking layer and the first and secondspacer parts may be formed by dry-film laminating processes in each ofwhich a resin film formed on a film is transferred to the transparentsubstrate.

In this structure, the color filter layer, the light-blocking layer andthe first and second spacer parts are formed by dry-laminatingprocesses, so that the thicknesses thereof are controlled with higheraccuracy than in the case of forming these films by conventional spincoating. Accordingly, the levels of the upper edges, i.e., the heights,of the first spacer part in the in-screen frame region and the secondspacer part in the in-screen display region are controlled withaccuracy.

The color filter substrate as described above exhibits its advantagesespecially in a display apparatus.

A display apparatus according to the present invention includes: a colorfilter substrate including a transparent substrate and a color filterlayer, the color filter layer being provided on the transparentsubstrate and made of a plurality of colored layers; an elementsubstrate being opposed to the color filter substrate and including atransparent substrate and a plurality of switching elements provided onthe transparent substrate; and a display medium layer sandwiched andheld between the color filter substrate and the element substrate,wherein an in-screen display region associated with the color filterlayer and an in-screen frame region located around the in-screen displayregion are defined in each of the color filter substrate and the elementsubstrate, a light-blocking layer is provided in the in-screen frameregion of the element substrate to cover the transparent substrate ofthe element substrate, the element substrate has a surface leveldifference resulting from the presence of the light-blocking layer,between the in-screen frame region and the in-screen display region, afirst spacer part and a second spacer part are formed in the in-screenframe region and the in-screen display region, respectively, of thecolor filter substrate to define the thickness of the display mediumlayer, and a height difference between the first spacer part and thesecond spacer part is substantially equal to the surface leveldifference between the in-screen frame region and the in-screen displayregion.

In this structure, the light-blocking layer is provided in the in-screenframe region of the element substrate, and the first and second spacerparts are formed in the in-screen frame region and the in-screen displayregion, respectively, of the color filter substrate so as to define thethickness of the display medium layer. In addition, the heightdifference between the first spacer part and the second spacer part issubstantially the same as the surface level difference between thein-screen frame region and the in-screen display region. Accordingly,the height difference between the first spacer part formed in thein-screen frame region and the second spacer part formed in thein-screen display region eliminates the surface level difference betweenthe in-screen frame region and the in-screen display region of theelement substrate. As a result, occurrence of color irregularities nearthe boundary between the in-screen display region and the in-screenframe region is suppressed.

In the display apparatus according to the present invention, the surfaceof the in-screen frame region of the element substrate may be at a levelhigher than that of the in-screen display region of the elementsubstrate, and the height of the first spacer part may be smaller thanthat of the second spacer part.

With this structure, if the surface of the in-screen frame region of theelement substrate is at a level higher than that of the in-screendisplay region of the element substrate because of the presence of thelight-blocking layer in the in-screen frame region of the elementsubstrate, the height of the first spacer part formed in the in-screenframe region is smaller than the second spacer part formed in thein-screen display region. This eliminates the surface level differencebetween the in-screen frame region and the in-screen display region ofthe element substrate.

In the display apparatus according to the present invention, the secondspacer part may be formed by stacking a material constituting the firstspacer part and a material constituting at least one of the coloredlayers in the color filter layer.

In this structure, the second spacer part in the in-screen displayregion is formed by stacking the material constituting the first spacerpart in the in-screen frame region and the material constituting atleast one of the colored layers in the in-screen display region.Accordingly, the height of the second spacer part is larger than that ofthe first spacer part by the thickness of the colored layer, so that thesurface level difference between the in-screen frame region and thein-screen display region of the element substrate is eliminated.

In the display apparatus according to the present invention, the displaymedium layer may contain liquid crystal molecules, and the in-screendisplay region of the color filter substrate may include a projectionmade of a material constituting the first and second spacer parts andused for controlling orientation of the liquid crystal molecules.

In this structure, a projection made of the material constituting thefirst and second spacer parts is provided in the in-screen displayregion, so that orientation of liquid crystal molecules is controlled byutilizing this projection.

In the display apparatus according to the present invention, the colorfilter layer, the light-blocking layer and the first and second spacerparts are formed by dry-film laminating processes in each of which aresin film formed on a film is transferred to the transparent substrate.

In this structure, the color filter layer, the light-blocking layer andthe first and second spacer parts are formed by dry-laminatingprocesses, so that the thicknesses thereof are controlled with higheraccuracy than in the case of forming these films by conventional spincoating. Accordingly, the levels of the upper edges, i.e., the heights,of the first spacer part in the in-screen frame region and the secondspacer part in the in-screen display region are controlled withaccuracy.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view showing a configuration in which aplurality of color filter substrates constituting a liquid crystal panelaccording to a first embodiment of the present invention are arranged ona mother glass.

FIG. 2 is a schematic plan view showing the liquid crystal panel.

FIG. 3 is a schematic cross-sectional view showing the liquid crystalpanel of the first embodiment.

FIG. 4 is a schematic plan view showing an active matrix substrate 1 aconstituting the liquid crystal panel of the first embodiment.

FIG. 5 is a schematic cross-sectional view showing the liquid crystalpanel of the first embodiment taken along the line V-V in FIG. 4.

FIG. 6 is a schematic cross-sectional view showing a liquid crystalpanel according to a second embodiment of the present invention andcorresponds to the schematic cross-sectional view of FIG. 3.

FIG. 7 is a schematic cross-sectional view showing a liquid crystalpanel according to a third embodiment of the present invention andcorresponds to the schematic cross-sectional view of FIG. 3.

FIGS. 8A through 8C are schematic cross-sectional views showingrespective process steps of fabricating a color filter substrateconstituting the liquid crystal panel of the third embodiment.

FIG. 9 is a schematic cross-sectional view showing a liquid crystalpanel according to a fourth embodiment of the present invention andcorresponds to the schematic cross-sectional view of FIG. 3.

FIG. 10 is a schematic cross-sectional view showing a liquid crystalpanel according to a fifth embodiment of the present invention andcorresponds to the schematic cross-sectional view of FIG. 3.

FIGS. 11A and 11B are graphs showing respective distributions of cellthicknesses in in-screen display regions of liquid crystal panelsfabricated according to an example of the present invention and acomparative example.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, embodiments of the present invention will be specificallydescribed with reference to the accompanying drawings. In the followingembodiments, liquid crystal display apparatuses using TFTs as switchingelements will be used as examples of display apparatuses. The presentinvention is not limited to the following embodiments and may have otherconfigurations.

Embodiment 1

Hereinafter, a liquid crystal display apparatus according to a firstembodiment of the present invention will be described.

FIG. 1 is a schematic plan view showing a configuration in which aplurality of color filter substrates 2 a constituting a liquid crystalpanel 10 are arranged on a mother glass 1. FIG. 2 is a schematic planview showing a peripheral part of the liquid crystal panel 10 in anenlarged manner. FIG. 3 is a schematic cross-sectional view of theliquid crystal panel. FIG. 4 is a schematic plan view showing a pixelpart of the liquid crystal panel. FIG. 5 is a schematic cross-sectionalview taken along the line V-V in FIG. 4. In FIG. 3, the configuration onan active matrix substrate 1 a is shown in a simplified manner.

During fabrication of a liquid crystal display apparatus, a plurality ofcolor filter substrates 2 a are arranged in a matrix pattern on themother glass 1, and each of the color filter substrates 2 a form a panelregion, thereby constituting a liquid crystal panel 10 a.

The liquid crystal panel 10 a includes: the active matrix substrate 1 afunctioning as an element substrate; the color filter substrates 2 aopposed to the active matrix substrate 1 a; and a liquid crystal layer 8sandwiched and held between these substrates 1 a and 2 a and forming adisplay medium layer.

In the active matrix substrate 1 a, a plurality of gate lines 15 and aplurality of source lines 16 are arranged on an insulating transparentsubstrate 9 to be orthogonal to each other. Between each two of the gatelines 15, a capacitor line 18 extends in parallel with the gate lines15. A TFT 21 is provided as a switching element at each intersectionbetween the gate lines 15 and the source lines 16. A pixel electrode 20constituting a pixel and associated with the TFT 21 is provided in eachdisplay region enclosed with a pair of the gate lines 15 and a pair ofthe source lines 16.

The active matrix substrate 1 a has a multilayer structure in which agate insulating film 23 and an interlayer insulating film 12 are stackedin this order over the insulating transparent substrate 9.

Between the insulating transparent substrate 9 and the gate insulatingfilm 23, the gate lines 15, gate electrodes 15 a projecting from thegate lines 15 in the direction along the source lines 16, the capacitorlines 18 and extended gate lines 11 as extensions of the respective gatelines 15 are provided.

Between the gate insulating film 23 and the interlayer insulating film12, a semiconductor layer 22 including an intrinsic amorphous siliconlayer 22 a and an n⁺ amorphous silicon layer 22 b stacked in this orderto constitute the TFTs 21 is provided, and the source lines 16 andsource electrodes 16 a associated with the respective TFTs 21 andprojecting from the source lines 16 along the direction of the gatelines 15, drain electrodes 17 opposed to the respective sourceelectrodes 16 a and extended drain electrodes 17 a as extensions of therespective drain electrodes 17 are provided on the semiconductor layer22.

The pixel electrodes 20 are provided on the interlayer insulating film12 and are connected to the extended drain electrodes 17 a via contactholes 19. An alignment film (not shown) is provided on the pixelelectrodes 20.

Parts of the extended drain electrodes 17 a located on the capacitorlines 18 serve as auxiliary capacitor electrodes and constituteauxiliary capacitors together with the associated capacitor lines 18 viathe gate insulating film 23.

Each of the color filter substrates 2 a has a multilayer structure inwhich a color filter layer 6 and a common electrode (not shown) arestacked in this order over the insulating transparent substrate 9.

Spacers oriented substantially perpendicularly to the insulatingtransparent substrate 9 are provided on the common electrode to definethe thickness of the liquid crystal layer 8 sandwiched and held betweenthe active matrix substrate 1 a and the color filter substrates 2 a.

A red layer 6 a, a green layer 6 b and a blue layer 6 c are provided inthe color filter layer 6 and each pixel of the active matrix substrate 1a is associated with one of these colored layers. A light-blocking layer13 that is a stack of the red layer 6 a and the blue layer 6 c and isthicker than the color filter layer 6 is provided in the periphery ofthe color filter layer 6 (i.e., in an in-screen frame region 4 that willbe described later.)

This light-blocking layer 13 is located in the in-screen frame region 4and thus has no direct relation with image display, but blocks lightfrom a backlight or the like necessary for image display in an in-screendisplay region.

The liquid crystal layer 8 is made of a nematic liquid crystal materialhaving an electro-optic property.

In this liquid crystal panel 10 a, a region where a plurality of pixelsare arranged in a matrix pattern, i.e., a region where the color filterlayers 6 of the color filter substrates 2 a are arranged in a matrixpattern, is defined as an in-screen display region 3. A region locatedaround the in-screen display region 3 and including the color filtersubstrates 2 a is defined as the in-screen frame region 4. A regionincluding no color filter substrates 2 a and including only the activematrix substrate 1 a is defined as an out-of-screen region.

The liquid crystal panel 10 a is mounted on a casing or a frame havingan opening such that the in-screen display region 3 and the in-screenframe region 4 are located in the opening and in a portion surroundingthe opening, respectively, thereby constituting a liquid crystal displayapparatus.

The spacers for the color filter substrates 2 a include first spacerparts 7 a provided in the in-screen frame region 4 and second spacerparts 7 b each provided between pixels in the in-screen display region3. The height of the first spacer parts 7 a is adjusted to be smallerthan that of the second spacer parts 7 b such that the sum of the heightof the first spacer parts 7 a and the thickness of the light-blockinglayer 13 is substantially equal to the sum of the height of the secondspacer parts 7 b and the thickness of the color filter layer 6.

The expression herein that the sum of the height of the first spacerparts 7 a and the thickness of the light-blocking layer 13 issubstantially equal to the sum of the height of the second spacer parts7 b and the thickness of the color filter layer 6 means that thedifference between these sums is 0.1 μm or less. If the differencebetween the sums is 0.1 μm or less in this way, variation of a colortone due to retardation is hardly perceived.

In this manner, the upper edge of the first spacer parts 7 a in thein-screen frame region 4 and the upper edge of the second spacer parts 7b in the in-screen display region 3 are substantially at the same level.Accordingly, the level difference occurring between the in-screen frameregion 4 and the in-screen display region 3 because of the presence ofthe light-blocking layer 13 provided in the in-screen frame region 4 ofeach of the color filter substrates 2 a is eliminated, so thatoccurrence of color irregularities near the boundary between thein-screen display region 3 and the in-screen frame region 4 issuppressed.

The liquid crystal panel 10 a is configured in the following manner. Onepixel is provided for each of the pixel electrodes 20. In the pixel,when a gate signal is sent from one of the gate lines 15 (the extendedgate lines 11) to turn the TFT 21 ON, a source signal from one of thesource lines 16 is sent via the source electrode 16 a and the drainelectrode 17 (the extended drain electrode 17 a) so that given charge iswritten in the pixel electrode 20 and a potential difference occursbetween the pixel electrode 20 and the common electrode of the colorfilter substrate 2 a. Accordingly, a given voltage is applied to liquidcrystal capacitor of the liquid crystal layer 8 and the auxiliarycapacitor. The liquid crystal panel 10 a displays an image whileadjusting the transmittance of light incident from a backlight or thelike by utilizing a change of orientation state of liquid crystalmolecules depending on the level of the applied voltage.

In this embodiment, TFTs made of amorphous silicon are used as switchingelements. Alternatively, TFTs made of microcrystal silicon, polysiliconor continuous grain silicon (CGS) or two-terminal switching elementswith, for example, metal insulator metals (MIM) structures.

Now, a method for fabricating a liquid crystal panel 10 a according tothe first embodiment of the present invention will be described.

<Process of Fabricating Active Matrix Substrate>

Hereinafter, a process of fabricating an active matrix substrateaccording to the first embodiment of the present invention will bedescribed with reference to the schematic plan view of FIG. 4 and theschematic cross-sectional view of FIG. 5.

First, a metal film (with a thickness of about 200 nm) made of aluminum(Al) is deposited by a sputtering process over the entire substrate,i.e., over the surface of an insulating transparent substrate 9 made of,for example, glass. Thereafter, patterning is performed by a photoengraving process (hereinafter, referred to as a PEP), thereby forminggate lines 15, gate electrodes 15 a, capacitor lines 18 and extendedgate lines 11.

Next, a silicon nitride film (with a thickness of about 400 nm), forexample, is deposited by a chemical vapor deposition (CVD) process overthe entire surface of the substrate including the gate lines 15, thegate electrodes 15 a, the capacitor lines 18 and the extended gate lines11, thereby forming a gate insulating film 23.

Then, over the entire substrate, i.e., over the surface of the gateinsulating film 23, an intrinsic amorphous silicon film (with athickness of about 150 nm) and an n⁺ amorphous silicon film (with athickness of about 50 nm) doped with phosphorus are successively formedby CVD processes. Subsequently, these films are patterned by a PEP intothe shape of islands on the gate electrodes 15 a, thereby forming asemiconductor layer 22 made of an intrinsic amorphous silicon layer 22 aand an n⁺ amorphous silicon layer 22 b.

Thereafter, a metal film (with a thickness of about 200 nm) made ofaluminum (Al) is deposited by a sputtering process over the entiresubstrate, i.e., over the surface of the gate insulating film 23 onwhich the semiconductor layer 22 has been formed. Then, the film ispatterned by a PEP, thereby forming source lines 16, source electrodes16 a, drain electrodes 17 and extended drain electrodes 17 a.

In this embodiment, the gate lines 15 and the source lines 16 are madeof aluminum (Al), as an example. However, the gate lines 15 and thesource lines 16 only need to be made of metal films having desiredelectric resistances. For example, a metal such as tantalum (Ta),titanium (Ti) or chromium (Cr) or an alloy containing these metals or amultilayer film as a stack of TaN (tantalum nitride)/Ta/TaN or Ti/Al/Ti,for example, may be used. Moreover, the source lines 16 is notnecessarily made of a general metal film and may also be made of atransparent conductive film of indium tin oxide (ITO) or othermaterials, for example.

Then, part of the n⁺ amorphous silicon layer 22 b in the semiconductorlayer 22 is removed by etching using the source electrodes 16 a and thedrain electrodes 17 as a mask, thereby forming channels.

Subsequently, the entire substrate including the source lines 16, thesource electrodes 16 a, the drain electrodes 17 and the extended drainelectrodes 17 a is coated with an acrylic positive photosensitivetransparent resin with a thickness of about 2.5 μm, thereby forming aninterlayer insulating film 12.

Then, parts of the interlayer insulating film 12 associated with theextended drain electrodes 17 a are removed by etching, thereby formingcontact holes 19.

Thereafter, a transparent conductive film (with a thickness of about 10nm) made of an ITO film is deposited by a sputtering process over theentire substrate, i.e., over the surface of the interlayer insulatingfilm 12. Subsequently, the film is patterned by a PEP, thereby formingpixel electrodes 20. Instead of the ITO film, a transparent conductivefilm such as an indium zinc oxide (IZO) film may be used as long as thisfilm has a desired electric resistance value.

Then, a polyimide resin is applied onto the entire substrate includingthe pixel electrodes 20 to a thickness of about 100 nm, thereby formingan alignment film.

In this manner, an active matrix substrate 1 a is fabricated.

<Process of Fabricating Color Filter Substrate>

Hereinafter, a process of fabricating a color filter substrate accordingto the first embodiment of the present invention will be described withreference to the schematic plan view of FIG. 2 and the schematiccross-sectional view of FIG. 3.

Before the process, dry films in each of which a resin film made of aphotosensitive resin (negative type) containing dispersed pigments ofred, green or blue is sandwiched and held between release films such aspolyethylene terephthalate (PET) films are prepared.

First, one of release films at one side of a red dry film is peeled off,the red dry film is bonded onto the insulating transparent substrate 9with the face thereof from which the release film has been peeled offpressed against the insulating transparent substrate 9, and then theother release film is peeled off. In this manner, a red photosensitiveresin film is transferred to the insulating transparent substrate 9.This process is a so-called thermal transfer process that is generallyperformed with a dry film heated. A method of transferring a resin filmonto a substrate is called a dry-film laminating method.

Next, the transferred red photosensitive resin film is exposed to lightusing a photomask and developed for pattern formation, thereby forming ared layer 6 a. The red layer 6 a is formed in a part of the in-screendisplay region 3 associated with given pixels and the entire region ofthe in-screen frame region 4.

Then, with respect to green, the same process as that for red isrepeated, thereby forming a green layer 6 b in a part of the in-screendisplay region 3 associated with given pixels.

Thereafter, with respect to blue, the same process as those for red andgreen is repeated, thereby forming a blue layer 6 c in a part of thein-screen display region 3 associated with given pixels and the entireregion of the in-screen frame region 4. In this manner, a light-blockinglayer 13 as a stack of the red layer 6 a and the blue layer 6 c isformed in the entire region of the in-screen frame region 4. That is,the light-blocking layer 13 is formed in the same process as those forthe red layer 6 a and the blue layer 6 c in the color filter layer 6, sothat the process of fabricating (forming) a color filter substrate 2 ais simplified. Out of the red, green and blue colored layers, thecombination of the red and blue colored layers exhibits the lowest lighttransmittance, so that the light-blocking layer 13 has a sufficientlight-blocking property by utilizing formation of the color filter layer6.

In the manner described above, the color filter layer 6 made of the redlayer 6 a, the green layer 6 b and the blue layer 6 c and thelight-blocking layer 13 are formed. The order of forming the red, greenand blue colored layers is not limited to the above order.

Then, a transparent conductive film (with a thickness of about 10 nm)such as an ITO film is deposited by a sputtering process over the entiresubstrate, i.e., over the color filter layer 6. Subsequently, the filmis patterned by a PEP, thereby forming a common electrode. Instead ofthe ITO film, a transparent conductive film such as an indium zinc oxide(IZO) film may be used as long as this film has a desired electricresistance value.

Thereafter, a photosensitive resin film is transferred to the entiresubstrate including the common electrode by a dry-film laminatingprocess.

Then, the transferred photosensitive resin film is exposed to lightusing a photomask and developed for pattern formation, thereby formingspacers including first spacer parts 7 a and second spacer parts 7 b. Atthis time, exposure time for the in-screen frame region 4 is set shorterthan that for the in-screen display region 3, so that the second spacerparts 7 b are formed in the in-screen display region 3 and the firstspacer parts 7 a having a height smaller than the second spacer parts 7b are formed and the in-screen frame region 4.

In this manner, the color filter layer 6, the light-blocking layer 13,the first spacer parts 7 a and the second spacer parts 7 b are formed bydry-film laminating processes, so that the thicknesses thereof arecontrolled with higher accuracy than in the case of forming these filmsby conventional spin coating. Accordingly, the levels of the upperedges, i.e., the heights, of the first spacer parts 7 a in the in-screenframe region 4 and the second spacer parts 7 b in the in-screen displayregion 3 are controlled with accuracy. In a case where the accuracy incontrolling the heights of the spacers does not need to be consideredstrictly, the color filter layer 6, the light-blocking layer 13, thefirst spacer parts 7 a and the second spacer parts 7 b may be formed notonly by dry-film laminating processes but also by spin coating processesor die coating processes.

Then, a polyimide resin is applied onto the entire substrate includingthe common electrode, thereby forming an alignment film.

In this manner, a color filter substrate 2 a is fabricated.

<Process of Fabricating Liquid Crystal Panel>

Hereinafter, a process of fabricating a liquid crystal panel accordingto the first embodiment of the present invention will be described.

First, a seal material such as a thermosetting epoxy resin is appliedonto the active matrix substrate 1 a or the color filter substrates 2 aby screen printing into a frame pattern lacking in a portioncorresponding to a liquid-crystal inlet.

Next, the active matrix substrate 1 a and the color filter substrates 2a are bonded together, the seal material is cured, and then the bondedsubstrates are divided into liquid crystal panel units, thereby formingempty cells.

Then, a liquid crystal material is injected by a low-pressure processinto a gap between the active matrix substrate 1 a and the color filtersubstrates 2 a in each of the empty cells, thereby forming a liquidcrystal layer 8. Thereafter, an UV-setting resin is applied to theliquid-crystal inlet and the UV-setting resin is cured with UVirradiation, thereby sealing the inlet.

In this manner, a liquid crystal panel 10 a according to the presentinvention is fabricated.

As described above, in the inventive liquid crystal display apparatus ofthe liquid crystal panel 10 a, the first spacer parts 7 a and the secondspacer parts 7 b are formed approximately perpendicular to theinsulating transparent substrate 9 in the in-screen frame region 4 andthe in-screen display region 3, respectively, of each of the colorfilter substrates 2 a. In addition, the height of the first spacer parts7 a is adjusted to be smaller than that of the second spacer parts 7 bby the thickness of the blue layer 6 c in such a manner that the sum ofthe height of the first spacer parts 7 a and the thickness of thelight-blocking layer 13 as a stack of the red layer 6 a and the bluelayer 6 c is equal to the sum of the height of the second spacer parts 7b and the thickness of the color filter layer 6. Accordingly, the upperedge of the first spacer parts 7 a in the in-screen frame region 4 andthe upper edge of the second spacer parts 7 b in the in-screen displayregion 3 are substantially at the same level. This eliminates the leveldifference between the in-screen frame region 4 and the in-screendisplay region 3 due to the presence of the light-blocking layer 13provided in the in-screen frame region 4 of each of the color filtersubstrates 2 a. As a result, occurrence of color irregularities near theboundary between the in-screen display region 3 and the in-screen frameregion 4 is suppressed.

Embodiment 2

Hereinafter, a liquid crystal display apparatus according to a secondembodiment of the present invention will be described.

FIG. 6 is a schematic cross-sectional view showing a liquid crystalpanel 10 b. This cross-sectional view corresponds to the schematiccross-sectional view of FIG. 3. As in FIG. 3, an active matrix substrate1 a shown in FIG. 6 is simplified in its structure on a substrate.

The liquid crystal panel 10 b includes: the active matrix substrate 1 afunctioning as an element substrate; color filter substrates 2 b opposedto the active matrix substrate 1 a; and a liquid crystal layer 8sandwiched and held between these substrates 1 a and 2 b and forming adisplay medium layer.

The active matrix substrate 1 a and the liquid crystal layer 8 aresubstantially the same as those described in the first embodiment, anddetailed description thereof will be omitted.

The color filter substrates 2 b are the same as the color filtersubstrates 2 a of the first embodiment in structure except for thestructure of second spacer parts 7 b. Hereinafter, the structure of thesecond spacer parts 7 b will be mainly described.

The second spacer parts 7 b are constituted by second-spacer lower layerportions 6 c′ and second-spacer upper layer portions 7 a′ and areprovided on a color filter layer 6. The second-spacer lower layerportions 6 c′ are made of a colored layer of a color different from thatof a colored layer on which the layer is formed. In the case of FIG. 6,the second spacer parts 7 b are formed on a green layer 6 b, so that thesecond-spacer lower layer portions 6 c′ are made of a blue layer 6 c.

The height of the second spacer parts 7 b is adjusted to be larger thanthat of the first spacer parts 7 a by the thickness of the second-spacerlower layer portions 6 c′. The sum of the height of the first spacerparts 7 a and the thickness of a light-blocking layer 13 as a stack of ared layer 6 a and the blue layer 6 c is substantially equal to the sumof the height of the second spacer parts 7 b as a stack of thesecond-spacer upper layer portions 7 a′ and the second-spacer lowerlayer portions 6 c′ and the thickness of the color filter layer 6.

As in the first embodiment, the expression, “substantially equal” meansthat the difference between the sums is 0.1 μm or less. If thedifference is 0.1 μm or less in this way, variation of a color tone dueto retardation is hardly perceived.

A method for fabricating the liquid crystal panel 10 b of the secondembodiment of the present invention is substantially the same as that inthe first embodiment. Therefore, only a method for fabricating the colorfilter substrates 2 b, which is a feature of the second embodiment, willbe described.

<Process of Fabricating Color Filter Substrate>

Hereinafter, a process of fabricating a color filter substrate accordingto the second embodiment of the present invention will be described withreference to the schematic cross-sectional view of FIG. 6.

As in the first embodiment, before the process, dry films in each ofwhich a resin film made of a photosensitive resin (negative type)containing dispersed pigments of red, green or blue is sandwiched andheld between release films such as polyethylene terephthalate (PET)films are prepared.

First, one of release films at one side of a red dry film is peeled off,the red dry film is bonded onto an insulating transparent substrate 9with the face thereof from which the release film has been peeled offpressed against the insulating transparent substrate 9, and then theother release film is peeled off. In this manner, a red photosensitiveresin film is transferred to the insulating transparent substrate 9.

Next, the transferred red photosensitive resin film is exposed to lightusing a photomask and developed for pattern formation, thereby forming ared layer 6 a. The red layer 6 a is formed in a part of an in-screendisplay region 3 associated with given pixels and the entire region ofan in-screen frame region 4.

Then, with respect to green, the same process as that for red isrepeated, thereby forming a green layer 6 b in a part of the in-screendisplay region 3 associated with given pixels.

Thereafter, with respect to blue, the same process as those for red andgreen is repeated, thereby forming a blue layer 6 c in a part of thein-screen display region 3 associated with given pixels, a part of thein-screen display region 3 associated with the green layer 6 b and theentire region of the in-screen frame region 4. In this manner, alight-blocking layer 13 as a stack of the red layer 6 a and the bluelayer 6 c is formed in the entire region of the in-screen frame region4. A color filter layer 6 made of the red layer 6 a, the green layer 6 band the blue layer 6 c is formed in the in-screen display region 3.Second-spacer lower layer portions 6 c′ are formed on the green layer 6b.

Then, a transparent conductive film (with a thickness of about 10 nm)such as an ITO film is deposited by a sputtering process over the entiresubstrate, i.e., over the color filter layer 6. Subsequently, the filmis patterned by a PEP, thereby forming a common electrode. Instead ofthe ITO film, a transparent conductive film such as an indium zinc oxide(IZO) film may be used as long as this film has a desired electricresistance value.

Thereafter, a photosensitive resin film is transferred to the entiresubstrate including the common electrode, by a dry-film laminatingprocess.

Then, the transferred photosensitive resin film is exposed to lightusing a photomask and developed for pattern formation, thereby formingfirst spacer parts 7 a and second-spacer upper layer portions 7 a′ inthe in-screen frame region 4 and the in-screen display region 3,respectively.

At this time, exposure times in the formations of the first spacer parts7 a and the second-spacer upper layer portions 7 a′ are the same, sothat the heights of the first spacer parts 7 a and the second-spacerupper layer portions 7 a′ are also the same. Since the second spacerparts 7 b are made of a film as a stack of the second-spacer lower layerportions 6 c′ and the second-spacer upper layer portions 7 a′, theheight of the second spacer parts 7 b is larger than that of the firstspacer parts 7 a by the thickness of the second-spacer lower layerportions 6 c′. Accordingly, the upper edge of the first spacer parts 7 ain the in-screen frame region 4 and the upper edge of the second spacerparts 7 b in the in-screen display region 3 are substantially at thesame level.

The order of forming the red, green and blue colored layers is notlimited to the above order.

Then, a polyimide resin is applied onto the entire substrate includingthe common electrode, thereby forming an alignment film.

In this manner, a color filter substrate 2 b is fabricated.

As described above, in the color filter substrates 2 b according to thepresent invention and the liquid crystal panel 10 b including the colorfilter substrates 2 b, the first spacer parts 7 a and the second spacerparts 7 b made of the second-spacer upper layer portions 7 a′ and thesecond-spacer lower layer portions 6 c′ are formed in the in-screenframe region 4 and the in-screen display region 3, respectively, of eachof the color filter substrates 2 b to be oriented substantiallyperpendicularly to the insulating transparent substrate 9. In addition,the height of the first spacer parts 7 a is adjusted to be smaller thanthat of the second spacer parts 7 b by the thickness of the blue layer 6c in such a manner that the sum of the height of the first spacer parts7 a and the thickness of the light-blocking layer 13 as a stack of thered layer 6 a and the blue layer 6 c is substantially equal to the sumof the height of the second spacer parts 7 b as a stack of the upperlayer portions 7 a′ and the lower layer portions 6 c′ and the thicknessof the color filter layer 6. Accordingly, the upper edge of the firstspacer parts 7 a in the in-screen frame region 4 and the upper edge ofthe second spacer parts 7 b in the in-screen display region 3 aresubstantially at the same level. In this manner, the level differenceoccurring between the in-screen frame region 4 and the in-screen displayregion 3 due to the presence of the light-blocking layer 13 provided inthe in-screen frame region 4 of each of the color filter substrates 2 bis eliminated, so that occurrence of color irregularities near theboundary between the in-screen display region 3 and the in-screen frameregion 4 is suppressed.

Embodiment 3

Hereinafter, a liquid crystal display apparatus according to a thirdembodiment of the present invention will be described.

FIG. 7 is a schematic cross-sectional view showing a liquid crystalpanel 10 c. This cross-sectional view corresponds to the schematiccross-sectional view of FIG. 3 used in the first embodiment. As in FIG.3, an active matrix substrate 1 a shown in FIG. 7 is simplified in itsstructure on a substrate.

The liquid crystal panel 10 c includes: the active matrix substrate 1 afunctioning as an element substrate; color filter substrates 2 c opposedto the active matrix substrate 1 a; and a liquid crystal layer 8sandwiched and held between the substrates 1 a and 2 c and forming adisplay medium layer.

The active matrix substrate 1 a and the liquid crystal layer 8 aresubstantially the same as those described in the first embodiment, anddetailed description thereof will be omitted.

Each of the color filter substrates 2 c has a structure in which a colorfilter layer 6 and a common electrode (not shown) are stacked in thisorder over an insulating transparent substrate 9.

In the color filter layer 6, each pixel of the active matrix substrate 1a is associated with one of colored layers of a red layer 6 a, a greenlayer 6 b and a blue layer 6 c, a black matrix 24 for preventing lightfrom reaching portions between these colored layers is provided betweenthe colored layers, and a light-blocking layer 13 thicker than the blackmatrix 24 is provided in an in-screen frame region 4 to surround thecolored layers and the black matrix 24.

Spacers oriented substantially perpendicularly to the insulatingtransparent substrate 9 are provided on the common electrode to definethe thickness of the liquid crystal layer 8 sandwiched and held betweenthe active matrix substrate 1 a and the color filter substrates 2 c.

These spacers are constituted by first spacer parts 7 a provided in thein-screen frame region 4 and second spacer parts 7 b associated withblack matrix 24 in an in-screen display region 3. The height of thefirst spacer parts 7 a is adjusted to be smaller than that of the secondspacer parts 7 b in such a manner that the sum of the height of thefirst spacer parts 7 a and the thickness of the light-blocking layer 13is substantially equal to the sum of the height of the second spacerparts 7 b and the thickness of the color filter layer 6 (black matrix24.)

As in the first and second embodiments, the expression, “substantiallyequal” means that the difference between these sums is 0.1 μm or less.If the difference is 0.1 μm or less in this way, variation of a colortone due to retardation is hardly perceived.

In this manner, the upper edge of the first spacer parts 7 a in thein-screen frame region 4 and the upper edge of the second spacer parts 7b in the in-screen display region 3 are substantially at the same level.

In addition, the black matrix 24 having the light-blocking property andprovided between the plurality of colored layers in the color filterlayer 6 overlays the second spacer parts 7 b in the in-screen displayregion 3. Accordingly, even if scattering or transmission of light iscaused by the second spacer parts 7 b, display quality in the screen isnot degraded.

A method for fabricating the liquid crystal panel 10 c according to thethird embodiment of the present invention is substantially the same asthat of the first embodiment. Therefore, only a method for fabricatingthe color filter substrates 2 c, which is a feature of the thirdembodiment, will be described with reference to FIG. 8.

<Process of Fabricating Color Filter Substrate>

Hereinafter, a process of fabricating a color filter substrate accordingto the third embodiment of the present invention will be described withreference to schematic cross-sectional views of FIGS. 7 and 8.

As in the first embodiment, before the process, dry films in each ofwhich a resin film made of a photosensitive resin (negative type)containing dispersed pigments of red, green or blue is sandwiched andheld between release films such as polyethylene terephthalate (PET)films are prepared.

First, one of release films at one side of a red dry film is peeled off,the red dry film is bonded onto the insulating transparent substrate 9with the face thereof from which the release film has been peeled offpressed against the insulating transparent substrate 9, and then theother release film is peeled off. In this manner, a red photosensitiveresin film is transferred to the insulating transparent substrate 9.

Next, the transferred red photosensitive resin film is exposed to lightusing a photomask and developed for pattern formation, thereby forming ared layer 6 a.

Then, with respect to green, the same process as that for red isrepeated, thereby forming a green layer 6 b in a part of the in-screendisplay region 3 associated with given pixels.

Thereafter, with respect to blue, the same process as those for red andgreen is repeated, thereby forming a blue layer 6 c in a part of thein-screen display region 3 associated with given pixels. In this manner,the red layer 6 a, the green layer 6 b and the blue layer 6 c are formedin the in-screen display region 3. The order of forming the red, greenand blue colored layers is not limited to the above order.

Then, a photosensitive resin film in which black pigments are dispersedis transferred by a dry-film laminating process onto the entiresubstrate to cover the red layer 6 a, the green layer 6 b and the bluelayer 6 c, thereby forming a black-matrix prototype film 25. Theblack-matrix prototype film 25 is approximately twice as thick as eachcolored layer.

Subsequently, as shown in FIG. 8A, the black-matrix prototype film 25 isexposed to light via the insulating transparent substrate 9 using thered layer 6 a, the green layer 6 b and the blue layer 6 c as a mask, sothat the black-matrix prototype film 25 between the colored layers andin the in-screen frame region 4 is cured, thereby forming a black-matrixprototype portion 24 a and a light-blocking-layer lower layer portion 13a.

Thereafter, as shown in FIG. 8B, a photomask 26 is positioned so as toprevent light from reaching the colored layers and the black-matrixprototype portion 24 a, i.e., the in-screen display region 3, and thenlight exposure is performed using the photomask 26. Subsequently, theblack-matrix prototype film 25 in the in-screen frame region 4 is cured,thereby forming a light-blocking-layer upper layer portion 13 b.

Then, development is performed, so that a black matrix 24 is formedbetween the red layer 6 a, the green layer 6 b and the blue layer 6 c asshown in FIG. 8C. In this manner, a color filter layer 6 including alight-blocking layer 13 in the in-screen frame region 4 is formed.

Then, a transparent conductive film (with a thickness of about 10 nm)such as an ITO film is deposited by a sputtering process over the entiresubstrate, i.e., over the color filter layer 6. Subsequently, the filmis patterned by a PEP, thereby forming a common electrode. Instead ofthe ITO film, a transparent conductive film such as an indium zinc oxide(IZO) film may be used as long as this film has a desired electricresistance value.

Thereafter, a photosensitive resin film for forming spacers istransferred to the entire substrate including the common electrode, by adry-film laminating process.

Then, the transferred photosensitive resin film is exposed to lightusing a photomask and developed for pattern formation, thereby formingspacers including first spacer parts 7 a and second spacer parts 7 b. Atthis time, exposure time for the in-screen frame region 4 is set shorterthan that for the in-screen display region 3, so that second spacerparts 7 b is formed in the in-screen display region 3 and first spacerparts 7 a having a height smaller than the second spacer parts 7 b areformed in and the in-screen frame region 4.

Then, a polyimide resin is applied onto the entire substrate includingthe common electrode, thereby forming an alignment film.

In this manner, a color filter substrate 2 c is fabricated.

As described above, in the color filter substrates 2 c according to thepresent invention and the liquid crystal panel 10 c including the colorfilter substrates 2 c, the first spacer parts 7 a and the second spacerparts 7 b are formed in the in-screen frame region 4 and the in-screendisplay region 3, respectively, of each of the color filter substrates 2c and are oriented substantially perpendicularly to the insulatingtransparent substrate 9. In addition, the height of the first spacerparts 7 a is adjusted to be smaller than that of the second spacer parts7 b by the thickness of the blue layer 6 c in such a manner that the sumof the height of the first spacer parts 7 a and the thickness of thelight-blocking layer 13 is substantially equal to the sum of the heightof the second spacer parts 7 b and the thickness of the color filterlayer 6 (black matrix 24.) Accordingly, the upper edge of the firstspacer parts 7 a in the in-screen frame region 4 and the upper edge ofthe second spacer parts 7 b in the in-screen display region 3 aresubstantially at the same level. This eliminates the level differencebetween the in-screen frame region 4 and the in-screen display region 3due to the presence of the light-blocking layer 13 provided in thein-screen frame region 4 of each of the color filter substrates 2 c, sothat occurrence of color irregularities near the boundary between thein-screen display region 3 and the in-screen frame region 4 issuppressed. In addition, the black matrix 24 with the light-blockingproperty overlays spacers (second spacer parts 7 b) in the in-screendisplay region 3. Accordingly, even if scattering or transmission oflight is caused by these spacers, display quality in the screen is notdegraded.

Embodiment 4

Hereinafter, a liquid crystal display apparatus according to a fourthembodiment of the present invention will be described.

FIG. 9 is a schematic cross-sectional view showing a liquid crystalpanel 10 d. This cross-sectional view corresponds to the schematiccross-sectional view of FIG. 3 used in the first embodiment. As in FIG.3, an active matrix substrate 1 a shown in FIG. 9 is simplified in itsstructure on a substrate.

The liquid crystal panel 10 d includes: the active matrix substrate 1 afunctioning as an element substrate; color filter substrates 2 d opposedto the active matrix substrate 1 a; and a liquid crystal layer 8sandwiched and held between the substrates 1 a and 2 d and forming adisplay medium layer.

The active matrix substrate 1 a and the liquid crystal layer 8 aresubstantially the same as those described in the first embodiment, anddetailed description thereof will be omitted.

The color filter substrates 2 d are the same as the color filtersubstrates 2 a of the first embodiment in structure except for thestructure of projections 28. Hereinafter, the structure of theprojections 28 will be mainly described.

The projections 28 are used for controlling orientation of liquidcrystal molecules constituting the liquid crystal layer 8 and areprovided on a color filter layer 6 in locations associated withrespective colored layers.

More specifically, the projections 28 are provided on a common electrode(not shown) on the color filter layer 6.

The projections 28 are made of a material constituting first spacerparts 7 a and second spacer parts 7 b. Accordingly, if exposure time fora part corresponding to the projections 28 is set shorter than the otherpart during light exposure of a photosensitive resin film for formingthe first spacer parts 7 a and the second spacer parts 7 b in processesof fabricating the color filter substrates of the first and thirdembodiments, the projections 28 are formed on the color filter layer 6(the common electrode.) Therefore, specific description of a process offabricating the color filter substrates 2 d will be omitted.

In addition to advantages obtained in the first embodiment, the colorfilter substrates 2 d according to the present invention and the liquidcrystal panel 10 d including the color filter substrates 2 d are capableof controlling orientation of liquid crystal molecules constituting theliquid crystal layer 8 by utilizing the projections 28 as describedabove.

Embodiment 5

Hereinafter, a liquid crystal display apparatus according to a fifthembodiment of the present invention will be described.

FIG. 10 is a schematic cross-sectional view showing a liquid crystalpanel 10 e. This cross-sectional view corresponds to the schematiccross-sectional view of FIG. 3 used in the first embodiment. As in FIG.3, an active matrix substrate 1 e shown in FIG. 10 is simplified in itsstructure on a substrate.

The liquid crystal panel 10 e includes: the active matrix substrate 1 efunctioning as an element substrate; color filter substrates 2 e opposedto the active matrix substrate 1 e; and a liquid crystal layer 8sandwiched and held between these substrates 1 e and 2 e and forming adisplay medium layer.

The active matrix substrate 1 e is substantially the same as the activematrix substrate 1 a of the first embodiment except for the structure ofa light-blocking layer 27 provided at the element-substrate side, andthe structure of the light-blocking layer 27 will be mainly described.

The light-blocking layer 27 at the element-substrate side is provided tocover TFTs 21, source lines 16 and the entire region of an in-screenframe region 4.

A part (not shown) of the light-blocking layer 27 located on TFTs 21blocks light striking on a semiconductor layer 22 (channel part) fromthe above, thus suppressing occurrence of leakage current by light.

A part of the light-blocking layer 27 located in the in-screen frameregion 4 is not directly related to image display because of itslocation, and blocks light from a backlight or the like necessary forimage display in an in-screen display region.

When the liquid crystal display apparatus is mounted on a casing or aframe, the part of the light-blocking layer 27 in the in-screen frameregion 4 is placed on a portion surrounding an opening of the casing orthe frame. Therefore, under consideration of a mounting margin, the partof the light-blocking layer 27 has a width (several millimeters) muchlarger than the width (about 10 μm) of the part of the light-blockinglayer 27 provided on the source lines 16.

In view of this, as shown in FIG. 10, in the in-screen display region 3,the surface of an interlayer insulating film 12 on the light-blockinglayer 27 is flat because the thickness of the narrow light-blockinglayer 27 is reduced as a following effect of reflowing a photosensitiveresin film constituting the interlayer insulating film 12. On the otherhand, in the in-screen frame region 4, the light-blocking layer 27 iswide, so that the following effect is small and, as a result, thesurface of the interlayer insulating film 12 is higher than that in thein-screen display region 3. This causes a level difference in thesurface of the interlayer insulating film 12 between the in-screendisplay region 3 and the in-screen frame region 4.

Unlike the light-blocking layer 13 of the color filter substrates 2 a inthe first embodiment, the color filter substrates 2 e include no bluelayer 6 c in the in-screen frame region 4.

Each of the color filter substrates 2 e has a multilayer structure inwhich a color filter layer 6 and a common electrode (not shown) arestacked in this order over an insulating transparent substrate 9.

Spacers oriented substantially perpendicularly to the insulatingtransparent substrate 9 are provided on the common electrode to definethe thickness of the liquid crystal layer 8 sandwiched and held betweenthe active matrix substrate 1 e and the color filter substrates 2 e.

These spacers are constituted by first spacer parts 7 a provided in thein-screen frame region 4 and second spacer parts 7 b provided betweenpixels in the in-screen display region 3. The height difference betweenof the first spacer parts 7 a and the second spacer parts 7 b issubstantially equal to the surface level difference between thein-screen frame region 4 and the in-screen display region 3.Accordingly, the height of the first spacer parts 7 a is adjusted to besmaller than that of the second spacer parts 7 b in such a manner as toeliminate the level difference in the surface of the interlayerinsulating film 12 between the in-screen display region 3 and thein-screen frame region 4. As a result, occurrence of colorirregularities near the boundary between the in-screen display region 3and the in-screen frame region 4 is suppressed.

As in the first, second and third embodiments, the expression,“substantially equal” means that the difference between these sums is0.1 μm or less. If the difference is 0.1 μm or less in this way,variation of a color tone due to retardation is hardly perceived.

The liquid crystal layer 8 is substantially the same as that in thefirst embodiment, and detailed description will be omitted.

Now, a method for fabricating a liquid crystal panel 10 e according tothe fifth embodiment of the present invention will be described.

<Process of Fabricating Active Matrix Substrate>

Hereinafter, a process of fabricating an active matrix substrateaccording to the fifth embodiment of the present invention will bedescribed with reference to the schematic cross-sectional view of FIG.10.

First, gate lines 15, gate electrodes 15 a, capacitor lines 18, extendedgate lines 11, a gate insulating film 23, a semiconductor layer 22,source lines 16, source electrode 16 a, drain electrodes 17, extendeddrain electrodes 17 a and channel parts (TFTs 21) of the semiconductorlayer are formed on an insulating transparent substrate 9 through theprocess steps described in the first embodiment.

Next, a photosensitive resin film in which black pigments are dispersedis transferred to the entire substrate by a dry-film laminating process,and then the film is patterned by a PEP to cover the source lines 16,the TFTs 21 and an in-screen frame region 4, thereby forming alight-blocking layer 27.

Subsequently, the entire substrate including the light-blocking layer 27and the extended drain electrodes 17 a is coated with an acrylicpositive photosensitive transparent resin with a thickness of about 2.5μm, thereby forming an interlayer insulating film 12.

Then, parts of the interlayer insulating film 12 associated with theextended drain electrodes 17 a are removed by etching, thereby formingcontact holes 19.

Thereafter, a transparent conductive film (with a thickness of about 10nm) made of an ITO film is deposited by a sputtering process over theentire substrate, i.e., over the interlayer insulating film 12.Subsequently, the film is patterned by a PEP, thereby forming pixelelectrodes 20. Instead of the ITO film, a transparent conductive filmsuch as an indium zinc oxide (IZO) film may be used as long as this filmhas a desired electric resistance value.

Then, a polyimide resin is applied onto the entire substrate includingthe pixel electrodes 20 to a thickness of about 100 nm, thereby formingan alignment film.

In this manner, an active matrix substrate 1 e is fabricated.

<Process of Fabricating Color Filter Substrate>

To fabricate the color filter substrates 2 e, it is sufficient to omitthe blue layer 6 c constituting the light-blocking layer 13 in thein-screen frame region 4 of the color filter substrates 2 a of the firstembodiment. Therefore, detailed description thereof will be omitted.

<Process of Fabricating Liquid Crystal Panel>

A process of fabricating a liquid crystal panel according to thisembodiment is the same as that in the first embodiment, and thusdetailed description thereof will be described.

In the foregoing manner, the liquid crystal panel 10 e according to thepresent invention is fabricated.

As described above, in the liquid crystal panel 10 e according to thepresent invention, the light-blocking layer 27 is provided in thein-screen frame region 4 of the active matrix substrate 1 e, and thefirst spacer parts 7 a and the second spacer parts 7 b are formed in thein-screen frame region 4 and the in-screen display region 3,respectively, of each of the color filter substrates 2 e to define thethickness of the liquid crystal layer 8. In addition, the height of thefirst spacer parts 7 a is adjusted to be smaller than that of the secondspacer parts 7 b so as to eliminate the level difference in the surfaceof the interlayer insulating film 12 between the in-screen displayregion 3 and the in-screen frame region 4. Accordingly, the heightdifference between the first spacer parts 7 a formed in the in-screenframe region 4 and the second spacer parts 7 b formed in the in-screendisplay region 3 eliminates the surface level difference between thein-screen display region 3 and the in-screen frame region 4 in theactive matrix substrate 1 e. As a result, occurrence of colorirregularities near the boundary between the in-screen display region 3and the in-screen frame region 4 is suppressed.

In the fifth embodiment, the light-blocking layer is provided in thein-screen frame region of the active matrix substrate in addition to thestructure of the first embodiment. However, the fifth embodiment isapplicable to the structures of the second, third and fourthembodiments.

Now, specific experiments will be described.

As an example of the present invention (hereinafter, referred to as aninventive example), a liquid crystal panel was fabricated in the samemanner as in the fifth embodiment.

Specifically, an active matrix substrate 1 e including a light-blockinglayer 27 with a thickness of 1.5 μm and an interlayer insulating film 12with a thickness of 2.5 μm was fabricated. Color filter substrates 2 ewere fabricated with the height of first spacer parts 7 a in anin-screen frame region 4 set at 3.0 μm and the height of the secondspacer parts 7 b in an in-screen display region 3 set at 3.4 μm. Thesesubstrates 1 e and 2 e were bonded together and a liquid crystalmaterial was injected into a gap between the substrates 1 e and 2 e andthe gap is sealed, thereby fabricating a liquid crystal panel.

Now, a comparative example will be described in comparison with theinventive example.

Specifically, color filter substrates were fabricated with the height ofspacers in an in-screen frame region and an in-screen display region setat 3.4 μm, and an active matrix substrate 1 e that is the same as thatused in the inventive example was prepared. Then, these substrates werebonded together and a liquid crystal material was injected into a gapbetween the substrates and the gap is sealed, thereby fabricating aliquid crystal panel.

Hereinafter, results of the inventive example and the comparativeexample will be described with reference to the graphs in FIGS. 11A and11B.

FIG. 11A is a graph showing distribution of cell thicknesses in thein-screen display region of the liquid crystal panel fabricated in thecomparative example. FIG. 11B is a graph showing distribution of cellthicknesses in the in-screen display region of the liquid crystal panelfabricated in the inventive example. The panel sizes of the liquidcrystal panels fabricated in the comparative example and the inventiveexample are both 15 inches. In FIGS. 11A and 11B, the cell thicknessesof each liquid crystal panels are measured at every given distance andthe results are plotted. The abscissa in each graph (including S1through S6) indicates the gate line direction of the liquid crystalpanel and the ordinate (including 1, 3 and 5) indicates the source linedirection of the liquid crystal panel.

The surface of the active matrix substrate 1 e had a surface leveldifference of 0.3 μm to 0.4 μm between the in-screen frame region andthe in-screen display region because of the presence of a light-blockinglayer 27 formed in the in-screen frame region 4 of the active matrixsubstrate 1 e.

In the comparative example, the height of the spacers was uniformbetween the in-screen frame region and the in-screen display region, sothat the cell thickness near the in-screen frame region is larger thanthat in a center portion of the in-screen display region depending onthe surface level difference of 0.3 μm to 0.4 μm described above.Accordingly, color irregularities were observed in a peripheral portionof the liquid crystal panel.

On the other hand, in the inventive example, the height of first spacerparts 7 a in the in-screen frame region 4 was set at 3.0 μm and theheight of second spacer parts 7 b in the in-screen display region 3 wasset at 3.4 μm, so that the above surface level difference of 0.3 μm to0.4 μm was eliminated. Accordingly, no difference was observed betweenthe cell thickness near the in-screen frame region and the cellthickness in a center portion of the in-screen display region, i.e., thecell thickness was almost uniform in the entire in-screen region. As aresult, the liquid crystal panel has an excellent display quality.

As described above, according to the present invention, occurrence ofcolor irregularities near the boundary between an in-screen displayregion and an in-screen frame region is suppressed, so that the presentinvention is useful for color liquid crystal display apparatuses.

1. A display apparatus comprising: a color filter substrate including atransparent substrate and a color filter layer, the color filter layerbeing provided on the transparent substrate and made of a plurality ofcolored layers; an element substrate being opposed to the color filtersubstrate and including a transparent substrate and a plurality ofswitching elements provided on the transparent substrate; and a displaymedium layer sandwiched and held between the color filter substrate andthe element substrate, wherein an in-screen display region associatedwith the color filter layer and an in-screen frame region located aroundthe in-screen display region are defined in each of the color filtersubstrate and the element substrate, a light-blocking layer is providedin the in-screen frame region of the element substrate to cover thetransparent substrate of the element substrate, the element substratehas a surface level difference resulting from the presence of thelight-blocking layer, between the in-screen frame region and thein-screen display region, a first spacer part and a second spacer partare formed in the in-screen frame region and the in-screen displayregion, respectively, of the color filter substrate to define thethickness of the display medium layer, and a height difference betweenthe first spacer part and the second spacer part is substantially equalto the surface level difference between the in-screen frame region andthe in-screen display region.
 2. The display apparatus of claim 1,wherein the surface of the in-screen frame region of the elementsubstrate is at a level higher than that of the in-screen display regionof the element substrate, and the height of the first spacer part issmaller than that of the second spacer part.
 3. The display apparatus ofclaim 1, wherein the second spacer part is formed by stacking a materialconstituting the first spacer part and a material constituting at leastone of the colored layers in the color filter layer.
 4. The displayapparatus of claim 1, wherein the display medium layer contains liquidcrystal molecules, and the in-screen display region of the color filtersubstrate includes a projection made of a material constituting thefirst and second spacer parts and used for controlling orientation ofthe liquid crystal molecules.
 5. The display apparatus of claim 1,wherein the color filter layer, the light-blocking layer and the firstand second spacer parts are formed by dry-film laminating processes ineach of which a resin film formed on a film is transferred to thetransparent substrate.